Abstract
In this paper, the finite element cutting simulation model with irregular distribution of multiple particles is established, the stress and strain distribution of SiC particles in the process of machining, as well as the material removal mechanism are analyzed. The effects of cutting velocity and feed per tooth on the surface quality of the material are also analyzed. The effect of feed per tooth on subsurface damage is revealed. The results show that in the micro-milling of SiCp/Al2024 composites, the particle removal form is mainly crushing and extraction. The surface defects of the workpiece mainly include pits, scratches, cracks, and extrusion damage. When the cutting velocity increases, the surface defects gradually change to crack, which can improve the surface quality of the workpiece. Increasing the feed per tooth will increase the surface defects of the workpiece and lead to poor surface quality. When the feed per tooth increased from 0.428 µm to 0.714 µm, the subsurface damage thickness increased from 35.2 µm to 47.3 µm.
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